NRC-IFCI's R&D program is aimed at advancing fuel cell science and technology and accelerating the commercialization of these technologies.

Our research programs utilize the following 5 core competencies as a foundation for our R&D effort. Almost 85% of the institute's S&T resources are allocated towards the development of these competencies, while the other 15% is leveraged through a portfolio of collaborative projects with cluster partners in Canada and abroad:

• Advanced Materials and Processing
• Modelling and Numerical Simulation
• Novel Architecture Design
• Prototyping & Systems Testing
• Sensors and Diagnostics Development

These competencies provide a solid foundation to deliver our mandate and achieve recognition for this institute in Canada, as well as internationally. Each competency in itself creates a synergy between the science, engineering and applications to our key R&D program areas, and demonstration projects.

Advanced Materials & Processes

This competency combines fundamental materials science (Noble and non-noble metal nano-catalysts and supports, ceramics and polymers), advanced process engineering (Reactive Spray Deposition and Ultrasonic Spray Pyrolysis) and novel architectures (metal supported fuel cells). The process engineering is aimed at developing micro and nanostructure materials with desired physical (thermal, mechanical), chemical and electrochemical properties that enable new architectures aimed at high performance, low cost and easy to manufacture polymer electrolyte membrane (PEM) and solid oxide fuel cell (SOFC) systems.

Modelling & Numerical Simulation

The NRC-IFCI modelling and numerical simulation group consists of eleven NRC researchers plus three secondment professors from Simon Fraser University, the University of Waterloo and the University of Victoria. This renowned group of researchers has established distinguished, world-class expertise in modelling-based design, enabling the optimization of PEM fuel cells, their components, and materials key to the generation of key knowledge, technology and its transfer to industry. In response to the emerging needs of clean and/or renewable energy, this group is now extending its core-expertise to cover the other clean and/or renewable energy areas.

NRC-IFCI modelling and numerical simulation capabilities span from the electronic level, to a nano and micro level, up to macro or system level modelling.

• At the micro level our expertise includes high throughout screening of materials through first-principle computer simulations, as well as computer-based rational design of advanced electrocatalyst materials for PEM fuel cells.
• At the nano- to meso-scale our activity covers solid and fluid mechanics, physical modelling of electro-chemical phenomena including mass and energy transfer, and microstructure formation and microstructure changes.
• At the individual cell and stack level, techniques such as the CFD (Computational Fluid Dynamics) are employed to model and analyze the continuous flow of fuels and oxidants throughout the system to optimize their design and improve their performance.
• At the full device level, techniques such as mass and energy balance are used to optimize the design of a fully operational device.
• At the fully integrated systems level, our competencies include process modelling and mathematics to perform "what-if" analysis of integrated energy systems such as hydrogen fuelling stations and hydrogen assisted renewable power systems.

In our modelling program, full relations between structure, properties and performance can be established, which in turn allows for the prediction of architectures of materials and operating conditions that optimize fuel cell operation.

For more information, please refer to our Modelling and Numerical Simulation Fact Sheet (Requires Adobe Acrobat Reader).

Novel Architecture Design

Improving performance, reducing costs, increasing durability and reliability, and improving manufacturability requires constant critical evaluation of alternative architectures and novel approaches. This competency spans the entire range of the fuel cell system and includes:

• Nanostructure of the materials used for the cathode, anode and electrolytes; and,
• Design of MEA, GDL, seals and assemblies including the flow fields.

Prototyping & System Testing

NRC-IFCI is constantly engaged in developing research prototypes ranging from individual cathode, anode or electrolyte, cells and stacks and sometimes even specialised test equipment fitted with sensing systems not usually required in production prototypes. The testing competency extends from testing and characterising materials, to performance testing of membranes and ceramics, catalysts, individual cells, all the way to fully integrated systems. This competency is used to support research projects, as well as for providing services to the industry for independent testing that may lead to the development of codes and standards.

Sensing & Diagnostics

Sensing and diagnostics are essential for fuel cell research and commercialization. At NRC-IFCI sensing and diagnostics involves developing sensing devices and systems for measuring parameters and performance of fuel cell systems. The development requires fundamental knowledge of materials, physics, chemistry, measurement techniques and engineering to integrate embedded sensing systems into fuel cell systems. Wide range concentration (1% to 100%), hydrogen sensor and alcohol (e.g., methanol and ethanol) concentration sensors have been developed for hydrogen and direct fuel cell systems.